Apparatus to tap the electrical signals in process control without breaking the continuity
A monitor can be installed in the terminal block having a monitor access opening. The installed monitor allows for current measurement without having to disconnect a wire from the terminal block. Similar monitors can measure voltage, detect ground loops, and provide continuous readings of circuit parameters. Embodiments can positively hold probe tips, transmit data over wires, or transmit data wirelessly. Make-before-break monitors allow parameters to be measured without ever breaking the monitored circuit. Break-before-make monitors allow the monitored circuit to be interrupted and then reconnected with a monitor in place.
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Embodiments are generally related to electric wiring, instrumentation signals, junction boxes, and terminal blocks.
BACKGROUNDElectrical terminal blocks provide a convenient way to pass electrical power or signals between individual electrical wires. A typical terminal block has one or more pairs of terminals with each pair being electrically connected. Each terminal has a connector, such as a machine screw, that can be tightened to hold a wire. An example of a prior art terminal block is shown in
Many terminal blocks have exposed wiring or circuitry that provides for a probe tip to be pressed onto the circuitry such that voltages can be read with a meter. Such diagnostics are helpful, but are limited and awkward. Systems and methods for improving diagnostics at a terminal block are needed.
SUMMARYThe following summary is provided to facilitate an understanding of some of the innovative features unique to the disclosed embodiments and is not intended to be a full description. A full appreciation of the various aspects of the embodiments disclosed herein can be gained by taking the entire specification, claims, drawings, and abstract as a whole.
It is, therefore, one aspect of the embodiments that a terminal block has a monitor access opening into which a monitor can be installed. The terminal block has a first wire connected to a left side terminal and a second wire connected to a right side terminal. The terminal block contains internal circuitry that directly conducts electrical signals between the first wire and the second wire. Directly conducts means a physical and conductive connection that can pass direct current from the first wire to the second wire and from the second wire to the first wire. The monitor, once installed, is held in place by the terminal block and includes circuitry for measuring or detecting the signal characteristics of the electrical signals. The signal characteristics can be any one of or include voltage, current, frequency, or another parameter. The circuitry on the monitor can include probe points, communications circuits, and measurement circuits.
It is another aspect of the embodiments that the terminal block has a terminal block body, a left circuit, and a right circuit. The terminal block body has a front side, back side, left side, right side, a monitor access opening, a left wire opening, and a right wire opening. The left circuit can be substantially inside the left side of the terminal block body and can include a left terminal, a left conductor, and a left spring loaded switch. The right circuit can be substantially inside the right side of the terminal block body and can include a right terminal, a right conductor, and a right spring loaded switch. A first wire can be attached to the terminal block by passing the first wire through the left wire opening and attaching it to the left terminal. Similarly, the second wire can be attached to the terminal block by passing it through the right wire opening and attaching it to the right terminal.
The left circuit can physically touch the right circuit when no monitor is installed in the terminal block. As such, there is direct physical and electrically conductive contact between the first and second circuit. An electrical signal can pass from left terminal to left conductor, to left spring loaded switch, to right spring loaded switch, to right conductor, to right terminal, and finally to the second wire. Certain embodiments can have only one spring loaded switch. Spring loaded switches can perform two functions. One function is pressing into a contact or other conductive element to thereby ensure an electrical connection. The second function is holding the monitor in place.
An installed monitor disrupts the physical connection between the first circuit and the second circuit. There is a direct physical and electrically conductive contact between the first circuit and the monitor's circuitry. There is also a direct physical and electrically conductive contact between the second circuit and the monitor's circuitry. The monitor's circuitry can pass electrical signals between the first circuit and the second circuit. Electrical signals can be control signals, control outputs, and control inputs as well as power inputs for powering a machine or device.
As an example, line current can pass through the first wire, into the terminal block, through the monitor, out the second wire, and to a device. The power return from the device can also pass through the terminal block, but must obviously traverse a different terminal pair. The power return can also pass through a monitor installed in the terminal block. In some embodiments, the same monitor can be installed between two sets of terminal pairs in a single terminal block such that the monitor can measure the power input, the power return, and a differential between the power input and power return.
It is an aspect of the embodiments that the monitors are “break before make” or “make before break.” The physical contact between the left circuit and right circuit is broken as the monitor is installed. Break before make means that the physical connection is broken before the electrical signal can pass through the monitor. As such, electrical communication between the first wire and second wire is briefly interrupted as the monitor is installed. Make before break means that the electrical signal can pass through the monitor and between the first circuit and the second circuit before the physical contact between the left and right circuits is broken. As such, electrical communication between the first wire and second wire is not interrupted as the monitor is installed.
It is a further aspect of the embodiments that the electrical signal can be measured. A monitor can provide a probe point that a measurement probe can be touched to such that a measurement can be made. Some probe tips can clamp onto suitable designed probe points. Some probe points can clamp onto a probe tip. Alternatively, a monitor can include measurement circuitry that can measure the voltage present on the first circuit, the voltage on the second circuit, or the current passing between the first and second circuit. The measurement can be communicated. Some monitors can have alphanumeric displays, bar displays, or other displays that indicate the measurements value. Some monitors can have indicators that light up or otherwise indicate that a signal (or power) is present, exceeds a certain value, is on, or is off. Some monitors can have circuitry for transmitting measured values to a receiver with the transmission being wired or wireless.
For example, a monitor can be inserted between two terminal pairs that provide AC line power and power return to a machine. The monitor can measure parameters including input line voltage, input line current, input frequency, return line voltage, return line current, return line frequency, phase difference between input and return, current difference between input and return, and voltage difference between input and return. Here, the monitor may be connected to a ground line or other ground reference. The monitor can display the measure parameters and can even have binary indicators showing that the machine is being powered and that there are no detectable ground faults. The monitor can also communicate the parameters, perhaps via WiFi, Bluetooth, or some other standardized wireless signal, to a smartphone or other device that can be configured to display, store, analyze, or alarm on the parameters as they change over time.
The accompanying figures, in which like reference numerals refer to identical or functionally-similar elements throughout the separate views and which are incorporated in and form a part of the specification, further illustrate the present invention and, together with the detailed description of the invention, serve to explain the principles of the present invention.
The particular values and configurations discussed in these non-limiting examples can be varied and are cited merely to illustrate at least one embodiment and are not intended to limit the scope thereof.
The embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the invention are shown. The embodiments disclosed herein can be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
A monitor can be installed on a terminal block having a monitor access opening. The installed monitor allows for current measurement without having to disconnect a wire from the terminal block. Similar monitors can measure voltage, detect ground loops, and provide continuous readings of circuit parameters. Embodiments can positively hold probe tips, transmit data over wires, or transmit data wirelessly. Make-before-break monitors allow parameters to be measured without ever breaking the monitored circuit. Break-before-make monitors allow the monitored circuit to be interrupted and then reconnected with a monitor in place.
The pads 1104, 1105 can be electrically connected to probe pads/terminals 1106, 1107 or measurement circuitry 1108. Depending on its configuration, measurement circuitry can measure a variety of electrical parameters such as the current flowing through terminal block 1101, the current flowing through terminal block 1102, the voltage at pad 1104, the voltage at pad 1105, the voltage difference between the pads 1104, 1105, or the difference between the currents flowing in blocks 1101, 1102. The measurement circuitry can control LED lights 1109 to indicate measurement values, circuit status, or circuit faults. The measurement circuitry can communicate measurements, perhaps in digital form, to communication circuitry 1110 which can send a wireless signal 1111 to a receiving device 1112. The receiving device 1112 can be a smartphone, tablet computer, or other device that receives the signal 1111 and displays the measurement values, circuit status, or circuit faults.
Monitor 1301 is illustrated as having two headers 1303 such that the monitor can be configured with different circuitry. For example, the measuring circuitry 1108 of
The monitor can be a populated circuit board with components, such as measurement circuits, traces, vias, and pads. A monitor can obtain power from a battery, parasitically from monitored power or control signals, from a power connection connected to a power source or some other means. A monitor monitoring two or more circuits can be powered by a voltage differential between any combinations of those circuits.
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure and all such modifications are intended to be included within the scope of the disclosure.
Claims
1. A system comprising:
- a terminal block comprising a terminal block body, left circuit, and right circuit; wherein the terminal block body comprises a front side, a back side, a right side, a left side, a monitor access opening, a left wire access opening, and a right wire access opening, wherein the left wire access opening is an opening in the left side, and wherein the right wire access opening is an opening in the right side;
- wherein the left circuit is located within the terminal block body and comprises a left terminal, a left conductor, and a left spring loaded switch;
- wherein the right circuit is located within the terminal block and comprises a right terminal, a right conductor, and a right spring loaded switch;
- wherein a first wire that is installed into the left terminal passes through the Sett wire access opening, is fixedly held by the left terminal, and is in electrical communication with the left terminal, left conductor, and left spring loaded switch;
- wherein a second wire that is installed into the right terminal passes through the right wire access opening, is fixedly held by the right terminal, and is in electrical communication with the right terminal, right conductor, and right spring loaded switch; wherein the Sett conductor is in physical contact with the left terminal: wherein the right conductor is in physical contact with the right terminal; wherein the left spring loaded blade is in physical contact with the left conductor; wherein the left circuit has a physical connection with the right circuit when a monitor is not installed in the terminal block such that the left circuit is in direct electrical contact with the right circuit; and
- wherein, when the monitor is installed in the terminal block, the monitor breaks the physical connection such that the left circuit is in direct physical and electrical contact with the monitor, the right circuit is in direct physical contact with the monitor, and the left circuit electrically communicates with the right circuit through the monitor.
2. The system of claim 1 further comprising the monitor wherein the monitor comprises conductive pads and circuitry arranged to “break before make” such that electrical communications between the first circuit and the second circuit are interrupted as the monitor is installed and as the monitor is removed.
3. The system of claim 1 further comprising the monitor, the monitor comprising:
- sensing circuitry that produces a measurement of a first circuit voltage, a second circuit voltage, or of a current wherein the current flows between the first circuit and the second circuit; and
- communications circuitry that accepts the measurement and transmits a digital measurement signal based on the measurement.
4. The system of claim 3 further comprising a receiving device wherein the receiving device wirelessly receives the measurement signal and displays the measurement signal to a person.
5. The system of claim 1 further comprising the monitor, wherein the monitor comprises a probe point that is located outside the terminal block when the monitor is installed, wherein the probe point is electrically connected to the first circuit or to the second circuit such that the probe point is at the same voltage as the first circuit or the second circuit.
6. The system of claim 1 further comprising the monitor,
- wherein the monitor comprises a first probe point and a second probe point;
- wherein the first probe point and the second probe point are located outside the terminal block when the monitor is installed;
- wherein the first probe point is electrically connected to the first circuit;
- wherein the second probe point is electrically connected to the second circuit; and
- wherein current flowing between the first circuit and the second circuit must also flow between the first probe point and the second probe point when the monitor is installed.
7. The system of claim 1 further comprising the monitor, the monitor comprising:
- sensing circuitry that produces a measurement of a first circuit voltage, of a second circuit voltage, or of a current wherein the current flows between the first circuit and the second circuit; and
- display elements wherein the display elements provide a visual indication of a value of the measurement.
8. A method comprising:
- inserting a monitor into a monitor access opening of a terminal block wherein the terminal block comprises a terminal block body, left circuit, and right circuit
- wherein the terminal block body comprises a front side, a back side, a right side, a left side, a monitor access opening, a left wire access opening, and a right wire access opening, wherein the left wire access opening is an opening in the left side, and wherein the right wire access opening is an opening in the right side;
- wherein the left circuit is located within the terminal block body and comprises a left terminal, a left conductor, and a left spring loaded switch;
- wherein the right circuit is located within the terminal block and comprises a right terminal and a right conductor;
- wherein a first wire that is installed into the left terminal passes through the left wire access opening, is fixedly held by the left terminal, and is in electrical communication with the left terminal, left conductor, and left spring loaded switch;
- wherein a second wire that is installed into the right terminal passes through the right wire access opening, is fixedly held by the right terminal, and is in electrical communication with the right terminal and right conductor;
- wherein the left conductor is in physical contact with the left terminal;
- wherein the right conductor is in physical contact with the right terminal;
- wherein the left spring loaded blade is in physical contact with the left conductor;
- wherein the left circuit is in direct physical and electrical contact with the right circuit before the monitor is inserted; and
- wherein, after the monitor is inserted, the left circuit is in direct physical and electrical contact with the monitor, the right circuit is in direct physical contact with the monitor, and the left circuit electrically communicates with the right circuit through the monitor.
9. The method of claim 8 wherein a second terminal block is positioned next to the terminal block, the method further comprising installing the monitor into the second terminal block while installing the monitor into the terminal block.
10. The method of claim 9 further comprising measuring a voltage difference between a first point on the monitor and a second point on the monitor wherein the first point is electrically connected to the first circuit of the terminal block and wherein the second point is connected to a first circuit of the second terminal block.
11. The method of claim 8 further comprising producing a measurement measuring a voltage of a point on the monitor wherein the point is directly electrically connected to the first circuit.
Type: Grant
Filed: Mar 22, 2016
Date of Patent: Sep 11, 2018
Patent Publication Number: 20170276706
Assignee: HONEYWELL INTERNATIONAL INC. (Morris Plains, NJ)
Inventors: Praveen Kumar Kajjam (Telangana), Murali Krishna Thavva.V.V (Telangana), Jaganmohan Y. Reddy (Telangana), Suresh Kumar Palle (Karnataka), Suresh Babu D T V S Dogiparthi (Telangana)
Primary Examiner: Tung X Nguyen
Assistant Examiner: Robert P Alejnikov, Jr.
Application Number: 15/077,240
International Classification: G01R 15/12 (20060101); G01R 19/25 (20060101); G01R 1/067 (20060101);